We took Dorn’s truck up to Beans Diesel Performance in Woodbury, Tennessee, to install the South Bend clutch kit. BDP technician Marty Meraz handled the installation in about eight and a half hours. An experienced DIYER— with the proper tools and equipment—could complete the clutch upgrade in a full day, either in a garage or on a flat driveway, but working on the ground will make the job a lot more difficult. Fortunately, the team at Beans has multiple truck lifts.
8 When he removed the pressure plate, Meraz noticed that there was some fairly significant heat build-up evident on the flywheel and pressure plate.
7 With the transmission secure, Meraz removes the bell housing bolts with an impact gun and the long extension with a wobble-socket to allow him to work at an angle and reach all of the mounting bolts. The transmission assembly could then be moved back...
2 After lifting the truck into the air, Meraz drains the old fluid from the transfer case to keep it from spilling during the clutch swap.
3 Then he unbolts the rear driveshaft from the rear axle and carrier-bearing mount before removing the shaft.
4 On the front side of the transfer case, Meraz unbolts the front driveshaft and secures it to the frame with a bungee cord; then he removes the linkage from the transfer case.
6 Before removing the transmission crossmember, Meraz supports the weight of the transmission and transfer case with a muffler jack. Then he removes the crossmember and secures the transmission assembly with a transmission jack, running a ratchet strap...
1 Marty Meraz starts by removing the shifter console and 4WD selector lever before removing the G56 shift lever. Notice the leaked transmission fluid from the torn shift boot: we’ll address an inexpensive replacement boot later.
5 The slave cylinder was easy to unbolt and remove from the driver side of the G56 transmission.